Tungsten Carbide Brief Introduction

There are three main compounds of binary tungsten-carbon system:
Tungsten monocarbide (WC)(shown as FIGUE.1), is the main constituent in most of the commercial cemented carbides, also commonly defined as tungsten carbide, is the only stable tungsten carbide at room temperature.  
Ditungsten carbide (W2C), can be used as a hard material.
Nonstoichiometric tungsten carbide (WC1-x), is an cubic high-temperature modification, which undergoes a eutectoid decomposition at 2530-2535℃ into β(W2C)+δ(WC).At room temperature it can only be obtained by rapid quenching in liquid tin.

tungsten carbide picture

Tungsten carbide have such advantages as follow:
1.High melting point and boiling point, the melting point of tungsten carbide is 2870℃ and the boiling point is 6000℃ under atmospheric pressure。
2.High hardness, tungsten carbide is a common hard phase of cememted carbide.
3.High density, the density of tungsten carbide is 15.63g/cm3.

High thermal expansion coefficient, the thermal expansion coefficient of tungsten carbide is 6.9×10-6/K.
4.High elastic modulus, the elastic modulus of tungsten carbide is 5 times than steel's.
Tungsten carbide powder is synthesized by tungsten powder and carbon black in a high frequency induction furnace or Carbon tube furnace at high temperature with or without hydrogen gas. Under hydrogen atmosphere, the carbonation reaction happened between tungsten and methane which is synthesized by carbon and hydrogen, otherwise the reaction will happened directly between tungsten and carbide.

Tungsten carbide have such applications as follow:
1.It is a common hard phase in cememted carbide;
2.Tungsten carbide is used as a raw material of compound carbide;
3.Tungsten carbide can apply as catalyst in organic chemistry and electrochemistry as catalyst.
4.It used as surface strengthening material such as cast tungsten carbide  and surface spraying material. 

 

Purity of Tungsten Powder

Purity of the tungsten powder is of particular importance in powder metallurgy manufacturing of tungsten metal and alloy, since the purity of subsequent products are mainly influenced by raw materials. Typical upper limits of foreign element concentrations by chinese national standard(GB) in µg/g are follow:

IMPURITIES OF TUNGSTEN POWDER

Since the remaining impurities after sintering significantly influencing the workability (grain boundary strenth, recrystallization temperature, grain size,etc.) and properties of the product, the impurities concentrations are strictly limitted in low level.

The purity of tungsten powder is mainly determined by the APT cleaness, since  the maximum purity at the stage of APT crystallization in production process is more or less reached. Sources of contaminations after APT processing

mainly contacts with metallic tubes or boats in the furnaces. Consequently the foreign elements such as Fe, Ni, Cr and Co, are slightly increasing.

 

Tungsten Powder Production Process

Tungsten powder is manufactured under strict quality control as raw materials of high density composites, diamond tools, metallizing paste, sintered parts of tungsten, etc. The manufature of tungsten powder is a key step in tungsten metal and alloy production, which significantly affect the properties of the subsequent products.

Production of tungsten powder is accomplished almost exclusively by the hydrogen reduction of tungsten oxides. The hydrogen reduction of tungsten halides and the carbon reduction of the tungsten oxides are presently not applied in industry on a large scale.

The common raw materials of tungsten powder reduction are tungsten trioxide and tungsten blue oxide(TBO), the latter  has been the most widely used material since 1970s. Also, tungstic acid(H2WO4), tungsten yellow oxide and tungsten purple oxide are only used in selected metal grades.

The reduction of tungsten oxides by hydrogen is the essential reaction in tungsten powder production process,which equation and reaction process are shown as follow:

WOX+XH2=W+XH2O

reduction of tungsten oxide

FIGURE1. Reduction process of tungsten oxide

The reduction can produce tungsten powder of grain size between 0.1 and 10μm starting from the same oxide precursor. 

 

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Geometrical Properties of Tungsten Powder

Tungsten powder is one of most important raw material for production of tungsten carbide, tungsten alloy, pure tungsten and the properties of it strongly affect performance of subsequent products .The geometrical properties of tungsten powder includes grain size, specific surface area, morphology of tungsten powder, etc.
tungsten powder photo
Grain size
The grain size of tungsten powder heavily influence the process of powder forming, sintering, machining and the performances of Final products. For instance grain size of tungsten carbide is mostly determined by the grain size of tungsten powder which is an raw material of tungsten carbide . Dry sieving method and Fisher method are commonly used in measuring tungsten powder’ grain size which often dived into 5 levels:
Ultracoarse particle: Average grain size>30μm;
Coarse particle: Average grain size 10-30μm;
Medium particle: Average grain size 3-10μm;
Fine particle: Average grain size 0.5-3μm;
Ultrafine particle: Average grain size <0.5μm.
 
Specific surface area
Specific surface area of tungsten powder directly determines the powder’s surface activation energy, which often used for evaluate powder’s average grain size. Commonly BET method for measuring specific surface area are applied for tungsten powder.
 
 

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